docElectric Drill Rigs Repower with 3500 Engines
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Electric Drill Rigs Repower with 3500 Engines
Electric Drill Rigs Repower with 3500 Engines Petroleum Division Caterpillar Power Systems Marketing Division Topics to Cover: • • • • • • • • • Electric Rig Advantages Why DC motors DC Drives SCR Drives Variable Frequency AC Drives Oilfield Bases – old & new Engine mounting Ratings Generators Electric Drill Rig Advantages • Drilling area quieter with engines farther away. • Less danger of igniting flammable gases. • Easier to move rig to new location. • Electrical control of torque limits provides better drilling control. • However: Electrical devices may require trained specialists. DC Motor Characteristics • Variable RPM operation. • Maximum torque at zero RPM. Good for drawworks. • Torque capability remains constant over the operating speed range. • DC motors are 800 to 1000 HP, and 800 Volt DC. Mudpump with DC motors Belt Drive Cooling Fan 800 HP DC motor Mudpump Drawworks with DC Motors 1000 HP DC motors Drawworks DC Motor Starting DC Drill Rig Characteristics • Oldest type of electric drill rig. • DC motor speed varies with DC voltage. • Requires a DC generator for each DC motor. • Non-current technology. • Best to repower and also upgrade to SCR technology. DC Drill Rig Power DC Generator AC Generator Replacement of engine may require moving all generators. DC Drill Rig Power Flow SCR Drill Rig • AC Generator output changed to DC with special Silicon Controlled Rectifiers. (SCR) • SCR contained in Switchgear house – not supplied by Cat. • 600 Volt AC rectifies to 800 volt DC. • DC motors remain the same as on DC rig. DC Motor Effect on AC Generator • Generator Power Factor varies with DC motor speed. PF varies from 0 PF to 1.0 PF • Requires oversize generators • Effectively 0.6 PF • We stamp 0.7 PF, but generator still oversized D399 SCR Modules Offshore Land Rig SCR Rig Power Flow SCR Drive Advantages • Advantages • Less Engines/Generators Required • Less Engines Running • No Auxiliary Generators • High Load on Engines • Response on Hoisting • Adjustable Torque Limits • Disadvantages • Cost • Complexity Variable Frequency AC Drive • Utilizes variable RPM AC Motors. • Not as common yet. • Eliminates brush maintenance of DC motors and eliminates drawworks brake. • AC generator does not have to be oversize, (with “diode front-end” system). Oilfield Bases • Over design required to maintain alignment and prevent vibrations. • I-beam bases, by themselves, have not proven successful. • Cat history: – 18 inch semi-boxed beams. – 21 inch boxed beams. – Tubular “base-within-a-base” design. A Day in the Life of an Oilfield Power Module Rig transportation between jobs can cause misalignment. So also can hull flexing on offshore drill rigs. Original 18 inch Cat base for DC drill rigs Some versions welded the engine deep oil pan into the base. These cannot be repowered with 3500 series. (Some did have 3 point mounting.) Special deep rails 18 inch Base 18-Inch Base 3500 Repower easily accomplished 3500 Repower cannot be accomplished because of added mounting blocks. 21-Inch Boxed Beam Base • Boxed beam provides alignment and resistance to vibration. • 3 point mounting isolates package from offshore rig hull movement. • 21 inch base was rarely used on land rigs because it was large, heavy and hard to 3 point mount. – Very easy to repower with 3500 series. 3-Point Mount Isolates External Forces 3-Point Mount 4-Point Mount 21-Inch Cat Oilfield Base 21-inch main beams. Cross beams & boxing. Engine supported on standard 10-inch rails. Entire base 3-point mounted to offshore rig. Caterpillar 21-Inch Base Deep Oil Pan Shallow Oil Pan Easily accommodates either deep or shallow oil pans. Works with 6.25 bore and 3500 series. 3500A on 21-Inch Base Mounting Blocks 3-Point Mount Replacing D399 only requires repositioning mounting blocks. Base-Within-A-Base • Consists of an inner and an outer base. • Inner base holds engine-to-generator alignment. • Built-in 3-point mount between inner and outer bases. • Two different outer bases used: – Land: • 25-, 30-, and 40-foot length – Offshore: • Lighter and lower than 21-inch base. Base-Within-A-Base Two Bases Included Inner tubular base removes 10-inch mounting rails. Inner Tubular Base Walkways 3-Point Mounts Outer Base 3500B Land Rig Power Module Walkways Tubular inner base 3-point mount (not visible) 30-foot outer base 3512B SCAC Land Power Module 30-Foot Base Dual Core Radiator SR4B Generator 3500B Offshore Power Module Inner Base Outer Base Drip Pan Built-in Spring Isolators Oil Drain Unique Application Inner base only sold for select applications. Special trailer power units. Repower Considerations D399 land rig has 7.12-inch wider oil pan than 3500 series. Base inserts would have to be added between 3500 series oil pan and existing inner base. Has been done. D398 repower with 3512 or 3508 would require drilling matching holes into the old inner base. Has been done. Candidate For 3512 Land Rig Repower! Additional Considerations Exhaust Roof Ladders Lights Power Cables Land SCR HP Ratings – 1200 RPM • • • • • • • • • • • • • D300 3516B 3516 3512B 3512 3512 D399 3512 3508B D398 912 3508 D379 3412E 3500A 3500B 1855 1804 1476 1434 1321 1215 950 912 860 610 587 Offshore SCR HP Ratings – 1200 RPM • • • • • • • D300 3516B HD 3516B 3512B D399 (SCAC) D399 (JWAC) D398 (JWAC) 1325 1215 912 3500B 2150 1855 1476 Offshore Engine Room Complexity 3516B Offshore Package JW Heat Exchanger Aftercooler Heat Exchanger Tilt Angle Requirements 25 degree capability for optional oil pan. Most Jackups: 10 Degrees Floaters: 15 Degrees Emergency Gen Sets: 22.5 Degrees Caterpillar Viscous Dampened Coupling for 2 Bearing Generators Driving Element Rubber Boot and Silicon Lubricant Driven Element SR4B Oilfield Generators • Oversize compared to EPG applications • Two bearing, independently supported • Form wound / VPI insulation – Class H – Resist electrical stresses • No voltage regulator • 10 OHM copper RTDs • 800 units in operation • SR4B spec sheet and EDS Cat SR4B Oilfield Generator • Reduced winding temperature rise rating • Provides safety margin for winding heating due to electrical waveform distortion • 80 C instead of 105 C rise • Oversized for 0.7 or 0.6 PF rating • Protects generator rotor from overheat at low PF • Capable of operating at even lower PF Waveform Distortion Recommended Oilfield Generator kVA Sizing • • • • • • • • • • • • • • • HP kVA (1200 RPM) 860 1000 915 1200 1210 1500 1321 1500 1435 1750 1476 1750 1804 2150 1855 2150 2150 2500 (1500 RPM) 1180 1500 1381 1500 1749 1900 (oversize) PF 0.61 0.55 0.58 0.63 0.58 0.60 0.60 0.62 0.61 0.56 0.65 0.65 Drill Rig Performance (Generator Sizing) • Oversize generators for the engine capability improves hoisting performance. • Oversize generators allows operation of mudpumps over a broader operating stroke range. • This can be verified with a rig power analysis performed for deep drilling (low PF), shallow drilling (high PF), and hoisting (variable PF). • Analysis needs to consider local rig operating customs. SR4B Generator Form Wound Stator – Class H Insulation SR4B Generator Exciter & Space for PMG SR4B Generator with Generator Air Filter Generator Special Items • Custom Quotes Possible • Quote Kato or Baylor as requested • Factory packaging warrants generator alignment. • Note: Published TMI SR4B generator exciter data is for 0.8 PF. Lower power factor requires more voltage regulator capacity. • • • • • • • • • • • • • • • Partial Consist: 3512B for Land SCR Rig Service 3512 Diesel Engine 1476 BHP 3512B Diesel Oilfield Engine Exhaust Elbow Spark Arresting Muffler 12 “ Engine Governor Control – 0 to 200 ma Generator SR4B, 1750 kVA Cable Access Box, RH Radiator Group – 46 CVS, 140 F Radiator Mounting Group Belt Guard Blower Fan Group Fan Drive Group Pulley Group Fumes Disposal Alarm Relay Panel 3512B HP01476 512DZ36 EXCEL08 MUFSA03 GOVPG08 OGNSEPD CAACBX1 RAD4621 RADMNT1 BLTGD1 FANB006 FDV0037 FANPL10 FUMDIS4 CQR item Alarm Relay Panel Provides remote alarm & additional alarm interfaces Partial Consist: 3516B for Offshore SCR Rig Service • • • • • • • • • • • • • • • 3516 Diesel Engine 1855 BHP 3516B Diesel Oilfield Engine Marine Society Arrangement Exhaust Elbow Spark Arresting Muffler Engine Governor Control – 0 to 200 ma Generator SR4B, 2150 kVA Cable Access Box, RH ABS – Engine ABS – Generator Fuel Cooler Alarm Relay Panel Engine Wiring J-Box Centrifugal Oil Filter Grid Switch 3516B HP01855 516DY11 ABSCONV EXCEL09 MUFSA02 GOVPG08 OGNSEP1 CAACBX1 MSABS23 CQR item CQR item CQR item CQR item CENTOF0 CQR item Grid Switch & Centrifugal Oil Filter Additional Requirements • Marine classification societies. – ABS – per the above partial consists – DNV, LR – certified coupling, Premium Wiring Harness • Computer system interfacing Partial Consist: 3516B HD for Offshore SCR Rig Service • • • • • • • • • • • • • • • • • • 3516 Diesel Engine 2150 BHP 3516B HD Diesel Oilfield Engine Oversize Mounting System – 3 point base Heat Exchanger System Marine Society Arrangement Exhaust Elbow Spark Arresting Muffler Engine Governor Control – 0 to 200 ma Kato Generator, 2500 kVA Coupling Hub High Tilt Oil Pan ABS – Engine ABS – Generator Fuel Cooler Alarm Relay Panel Engine Wiring J-Box Centrifugal Oil Filter Grid Switch 3516B HP02150 516DY07 CQR item CQR item ABSCONV EXCEL13 MUFSA01 GOVPG08 CQR item COUHUB1 CQR item MSABS24 CQR item CQR item CQR item CQR item CENTOF0 CQR item Oversize Mounting System & Heat Exchangers, High Tilt Oil Pan Semi-submersibles Require 15 Degree Tilt Oil Pans 3516B HD Applications 2150 BHP • Achieve 10,000 HP in 5 engines. – Large land rigs and some jackups • Repower large competitive engines – Less expensive than 3600 series. – Roots blown EMDs • 16-645 is 2200 HP roots blown – Alco, Fairbanks Morse, SACM • Savings in weight, space, noise, emissions, new cost and reduced operational cost.
